Photovoltaic array mounting apparatus, systems, and methods

ABSTRACT

A photovoltaic array, including: (a) supports laid out on a surface in rows and columns; (b) photovoltaic modules positioned on top of the supports; and (c) fasteners connecting the photovoltaic modules to the supports, wherein the supports have an upper pedestal surface and a lower pedestal surface such that the photovoltaic modules are positioned at a non-horizontal angle when edges of the photovoltaic modules are positioned on top of the upper and lower pedestal surfaces, and wherein a portion of the fasteners rotate to lock the photovoltaic modules onto the supports.

CROSS REFERENCES

The present application is a continuation-in-part of U.S. patentapplication Ser. No. 14/137,989, entitled Photovoltaic Array MountingApparatus, Systems, and Methods, filed Dec. 20, 2013. The presentapplication also claims the benefit of the filing dates of U.S.Provisional Patent Application Ser. No. 61/841,381, entitledPhotovoltaic Array Mounting Apparatus, Systems, and Methods, filed Jun.30, 2013, and U.S. Provisional Patent Application Ser. No. 61/740,410filed Dec. 20, 2012. The foregoing applications are incorporated byreference in their entirety as if fully set forth herein.

GOVERNMENT INTEREST

The present application was made pursuant to U.S. Department of EnergyGrant DE-EE0005439. The government may have certain rights in thisinvention.

BACKGROUND

Photovoltaic (PV) arrays are formed by mechanically linking together PVmodules into an array. Most PV module mounting and grounding systemsrequire the time-consuming use of multiple small fasteners. High partcount and slow installation time is a major barrier to reducing PVsystem costs and adoption. Some attempts have been made to reduce PVsystem costs and adoption. However, these systems suffer from a numberof drawbacks. For example, known mounting and grounding devices requirea special flange on the outside of the PV module frame and/or requirespecially designed tools for installation. Other mounting and groundingsystems are not compatible with different types of roofs or structures.Other mounting and grounding systems require a high part count and, as aresult, have higher costs. Others are not compatible with grooved PVmodules or PV modules comprising a substantially flat outward facingsurface on the frame. And still, others do not provide a reliableelectrical ground bond between the support base and PV modules.

The foregoing examples of the related art and limitations relatedtherewith are intended to be illustrative and not exclusive. Otherlimitations of the related art will become apparent to those of skill inthe art upon a reading of the specification and a study of the figures.

SUMMARY

The following embodiments and aspects thereof are described andillustrated in conjunction with systems, apparatus, tools, and methodswhich are meant to be exemplary and illustrative, not limiting in scope.In various embodiments, one or more of the above-described problems havebeen reduced or eliminated, while other embodiments are directed toother advantages or improvements.

One embodiment of the invention comprises an apparatus for mounting aphotovoltaic (PV) module on a surface, comprising a support with anupper surface, lower surface, tabs, and openings, and a clip with an armand a notch, where the apparatus resists wind forces and seismic forcesand creates a grounding electrical bond between the PV module, support,and clip. One embodiment of the invention further comprises a method forinstalling PV modules on a surface that includes arranging supports inrows along an X axis and in columns along a Y axis on a surface suchthat in each row such that in each row the distance between twoneighboring supports does not exceed the length of the longest side of aPV module and in each column the distance between two neighboringsupports does not exceed the length of the shortest side of a PV module,placing a PV module upon the supports such that each corner of the frameof the PV module rests on a support, and connecting the supports to thePV module by engaging a clip to at least a portion of the frame of thePV module and to the support. One embodiment of the invention furthercomprises an apparatus for mounting a PV module on a surface, comprisinga support with an upper surface, lower surface, tabs, and openings, aclip with an arm and a notch, and a bracket. One embodiment of theinvention additionally comprises a method for installing a PV module ona surface that includes arranging supports in rows along a X axis and incolumns along a Y axis on a surface such that in each row the distancebetween two neighboring supports does not exceed the length of thelongest side of a PV module and in each column the distance between twoneighboring supports does not exceed the length of the shortest side ofa PV module, placing a PV module upon the supports such that each cornerof the frame of the PV module rests on a support, connecting thesupports to the PV module by engaging a clip to at least a portion ofthe frame of the PV module and to the support, and securing a bracket toa support and to the surface or structure.

In addition to the exemplary aspects and embodiments described above,further aspects and embodiments will become apparent by reference to thefigures and by study of the following detailed descriptions.

BRIEF DESCRIPTION OF THE DRAWINGS

Demonstrative embodiments are illustrated in referenced figures anddrawings. It is intended that the embodiments and figures disclosedherein are to be considered illustrative rather than restrictive.

FIG. 1 is an isometric view of a PV array on a flat or low-slopesurface.

FIG. 2 is a close up of a portion of FIG. 1.

FIG. 3 is an isometric view of a clip.

FIGS. 4-6 are progressive views of a clip engaging a frame and asupport.

FIG. 7 is an orthogonal view of the stages of position of a clip as itengages a frame and a support.

FIG. 8 is an isometric view of a portion of a PV array with a winddeflector installed.

FIG. 9 is an orthogonal view of a PV array on a flat or low-slopesurface.

FIG. 10 is an enlargement of a portion of FIG. 9.

FIG. 11 is an orthogonal view of a portion of a PV array on a flat orlow-slope surface.

FIG. 12 is an isometric view of a portion of a PV array on a flat orlow-slope surface.

FIG. 13 is an isometric view of a support connected to the groove of aPV module frame by a clip.

FIG. 14 is an isometric view of a bracket connecting a PV array to asurface.

FIG. 15 is an orthogonal view of the contents of FIG. 14.

FIG. 16 is a perspective view of a PV system with an alternate bracket.

FIG. 17 is an orthogonal view of the contents of FIG. 16.

FIG. 18 is an isometric view of a PV array on a flat or low-slopesurface where the frames of the PV modules lack grooves.

FIGS. 19-21 are progressive views of a clip engaging a frame and asupport where the frame lacks a groove.

FIG. 22 is an orthogonal view of a PV array on a flat or low-slopesurface where the PV modules lack a groove.

FIG. 23 is an enlargement of a portion of FIG. 22.

FIG. 24 is a perspective view of a PV module mounted in portraitposition.

FIG. 25 is a perspective view of two adjacent PV modules mounted inportrait position.

FIG. 26 is a perspective view of a clip.

FIG. 27 is an incline view of two clips installed between two adjacentPV modules.

FIG. 28 is a bottom view of two clips installed between two adjacent PVmodules.

FIG. 29 is a perspective view of a clip.

FIG. 30 is a perspective view of a PV module mounted in portraitposition.

FIG. 31 is an enlarged view of a portion of FIG. 30.

FIG. 32 is a perspective view of two adjacent PV modules mounted inportrait position.

FIG. 33 is an isometric view of two consecutive PV modules mounted inportrait position.

FIG. 34 is an enlarged view of a portion of FIG. 33.

FIG. 35 is an enlarged view of a portion of FIG. 33.

FIG. 36 is a perspective view of an alternate embodiment of a PV arrayfor a flat or low-sloped surface.

FIG. 37 is an enlarged view of a portion of FIG. 36.

FIG. 38 is a perspective view of a PV array with ballast.

FIG. 39 is another view of a PV array with ballast.

FIG. 40A is a front elevation view of a fastener for connecting thephotovoltaic modules to the supports.

FIG. 40B is a side elevation view of the fastener of FIG. 40A.

FIG. 40C is a front elevation view of the hook portion of the fastener.

FIG. 40D is a side elevation view of the hook portion of the fastener.

FIG. 40E is a perspective view of the hook portion of the fastener.

FIG. 40F is a perspective view of the coupling portion of the fastener.

FIG. 40G is a front elevation view of the coupling portion of thefastener.

FIG. 40H is a side elevation view of the coupling portion of thefastener.

FIG. 41A is a perspective view of the fastener rotated to lock into aside groove in a photovoltaic module frame.

FIG. 41B is a side elevation view corresponding to FIG. 41A.

DETAILED DESCRIPTION OF ONE OR MORE EMBODIMENTS OF THE INVENTION

Terms. With reference to the figures and description herein but withoutlimitation:

Adjacent refers to being positioned next to or adjoining or neighboring,or having a common vertex or common side. Thus, adjacent PV panels wouldinclude PV panels that have one side close to (from a few inches apartto abutting) and facing one side of another PV panel. Sometimes, but notalways, the corners of adjacent panels align; so four adjacent panelswould have one corner each that nearly or actually touch the other threecorners.

Adjustable refers to the capability of being changed so as to match orfit.

Adjustably connected refers to an object, item, mechanism, apparatus,combination, feature, link or the like that loosely, slidable, orrigidly links, interlocks, joins, unites or fastens two or more thingstogether in a manner that can be changed so as to match or fit.

Attach or attachment refers to one or more items, mechanisms, objects,things, structures or the like which are joined, fastened, secured,affixed or connected to another item, or the like in a permanent,removable, secured or non-permanent manner.

Axis of rotation refers to a center around which something rotates,sometimes considered a straight line through all fixed points of arotating rigid body around which all other points of the body move in acircular manner.

Beneath refers to extending or being situated directly or substantiallyunderneath, typically with close proximity or contact.

Between refers to being situated, located, or otherwise oriented at, in,or across the space separating two objects or regions.

Connect or connecting refers to loosely, slidably, or rigidly bringingtogether or into contact with or joining or fastening to form a link orassociation between two or more items, mechanisms, objects, things,structures or the like.

Connector refers to an object, item, mechanism, apparatus, combination,feature, link or the like that loosely, slidable, or rigidly links,interlocks, joins, unites or fastens two or more things together. Mayalso include a device, an object, item, mechanism, apparatus,combination, feature, link or the like for keeping two parts of anelectric or electronic circuit in contact.

Coplanar refers to the circumstance where two or more objects aresituated, located, or otherwise substantially oriented in the sameplane.

Couple refers to loosely, slidably, or rigidly joining, linking,interlocking, connecting or mating two or more objects or items,mechanisms, objects, things, structures or the like together.

Coupling refers to an object, item, mechanism, apparatus, combination,feature, link or the like that loosely, slidably, or rigidly joins,links, mates, interlocks, or connects two things together.

Double male connector refers to a connector (see above) having two maleor insertable members, usually used for connecting two female orreceiving parts or coupling members together.

Disengage refers to detaching, freeing, loosening, extricating,separating or releasing from something that holds-fast, connects,couples or entangles. See Engagement below.

Enable refers to facilitating or making possible, able, feasible,practical, operational, or easy; or to cause to operate.

End refers to a final part, termination, extent or extremity of anobject, item, mechanism, apparatus, combination, feature, or the likethat has a length.

Engage refers to interlocking or meshing or more items, mechanisms,objects, things, structures or the like. See Disengage above.

Frame refers to an essentially rigid structure that surrounds orencloses a periphery of an item, object, mechanism, apparatus,combination, feature, or the like.

Freely refers to being without or exempt from substantial restriction orinterference by a given condition or circumstance. May also refer tobeing unobstructed, unconstrained, unrestricted or not being subject toexternal restraint.

Gap refers to a break, void, opening, cleft, breach, aperture,separation, or space, as well as an interruption of continuity, betweentwo objects, or within an object.

Groove refers to a long, narrow cut, rut, indentation, channel, furrow,gutter, slot or depression often used to guide motion or receive acorresponding ridge or tongue.

Height adjustable refers to change or adapt to bring items, objects,mechanisms, apparatus, combinations, features, components or the likeinto a proper, desired or preferred relationship of a distance orelevation above a recognized level, such as the ground or a supportsurface.

Insertable refers to an object, item, mechanism, apparatus, combination,feature, link or the like which is capable of being put in, enteredinto, set within, introduced, inset, inserted, placed, fit or thrustinto another an object, item, mechanism, apparatus, combination,feature, link or the like.

Integral with refers to being essential or necessary for completeness,constituent, completing, containing, entire, or forming a unit. May alsorefer to consisting or composed of parts that together constitute awhole.

Laminate or PV laminate refers to a photovoltaic device having aninterconnected assembly of solar cells, also known as photovoltaic cellswhich is frequently, but not always, laminated with glass and/or othermaterials.

Length refers to a measurement or extent of an object, item, mechanism,apparatus, combination, feature, link or the like from end to end,usually along the greater or longer of the two or three dimensions ofthe body; in distinction from breadth or width.

Located refers to where an object or a series of objects is physicallysituated with respect to one or more other objects.

Locked refers to fastened, secured or interlocked.

Orthogonally refers to relating to or composed of right angles,perpendicular or having perpendicular slopes or tangents at a point ofintersection.

Near refers to a short distance from an object or location.

Perimeter refers to an essentially continuous line forming the boundary,periphery or circuit of a closed geometric figure; the outer limits ofan area.

Photovoltaic module (sometimes referred to as a PV module, solar panel,solar module, or photovoltaic panel) refers to a packaged,interconnected assembly of solar cells, also known as photovoltaiccells, frequently, but not always, laminated with glass and othermaterials and sometimes surrounded by a frame. A plurality of PV modulesare commonly used to form a larger photovoltaic system referred to as aPV array (see below), to provide electricity for commercial, industrialand residential applications.

Pivotally refers to or relates to an object, item, mechanism, apparatus,combination, feature, link or the like serving as a pivot or the centralpoint, pin, shaft or contact on which another object, item, mechanism,apparatus, combination, feature, link or the like turns, swings, rotatesor oscillates.

Positionable refers to an object, item, mechanism, apparatus,combination, feature, link or the like which is capable of beingpositioned, placed or arranged in a particular place or way.

Preload refers to the force that must be overcome to separate a jointonce force is applied to attach a coupling to the joint. The appliedforce deforms the coupling and/or one or more of the components of thejoint and becomes the force that must be overcome to separate the joint.

PV laminate refers to a photovoltaic device having an interconnectedassembly of solar cells, also known as photovoltaic cells which isfrequently, but not always, laminated with glass and/or other materials.A PV laminate with an integral frame which may support the PV laminateis sometimes referred to as a PV module.

PV module refers to a photovoltaic module (sometimes referred to as asolar panel or photovoltaic panel) is a packaged interconnected assemblyof solar cells, also known as photovoltaic cells, frequently, but notalways, laminated with glass and other materials and sometimessurrounded by a frame. A plurality of PV modules are commonly used toform a larger photovoltaic system referred to as a PV array (see below),to provide electricity for commercial, industrial and residentialapplications.

PV array refers to a plurality of photovoltaic modules connectedtogether often in a pattern of rows and columns with module sides placedclose to or touching other modules.

Rail refers to a relatively straight, usually essentially evenly shapedalong its length, rod, beam, girder, profile or structural member or thelike, or plurality of such, of essentially rigid material used as afastener, support, barrier, or structural or mechanical member.

Rail member refers to a structural entity, element or unit (or part ofsuch entity, element, or unit) that acts as or embodies a rail.

Removable refers to one or more items, mechanisms, objects, things,structures or the like which are capable of being removed, detached,dismounted from or taken-away from another item or the like, orcombination.

Rectilinear refers to one or more items, mechanisms, objects, things,structures or the like which are essentially bounded by, characterizedby or forming straight and substantially parallel lines.

Rigidly couples refers to joining, linking, connecting or mating two ormore objects or items, mechanisms, objects, things, components,structures or the like together in a non-flexible manner that isdifficult to bend or be forced out of shape.

Roof refers to a structure or protective covering that covers or formsthe upper covering or top of a building. The upper surface of a roof isoften used as a support surface for mounting, connecting or otherwiseattaching a PV module or a PV array.

Rotatably refers to one or more items, mechanisms, objects, things,structures or the like which are capable of being rotated, revolved orturned around or about an axis or center.

Skirt refers to an edging, molding or covering that may be fixed to theedge of a PV module to conceal or block the bottom area under a PV arraywhen the PV array is mounted to a support surface.

Span refers to an extent or measure of space between, or the distancebetween two points or extremities.

Support or supporting refers to one or more items, mechanisms, objects,things, structures or the like which are capable of bearing weight orother force, often to keep the item or the like from falling, sinking,slipping or otherwise moving out of a position.

Support structure refers to a structure, such as a roof, table or theground which may provide a base for securing PV modules to form a PVarray.

Threaded refers to one or more items, mechanisms, objects, things,structures or the like which have, embody or include an essentiallyhelical or spiral ridge or rib, as on a screw, nut, or bolt.

Various locations refers to places, positions or sites that aredifferent from one another, more than one, individual or separate.

Vertical height adjustment refers to change or adapt to bring items,mechanisms, objects, things, components, structures or the like orcomponents into a proper, desired or preferred relationship of adistance or elevation above a recognized level, such as the ground or asupport surface.

Width refers to the state, quality, or fact of being wide or ameasurement or extent of something from side to side; in distinctionfrom breadth or length.

FIGS. 1-11 show an embodiment of a photovoltaic (PV) system 20 formounting PV arrays on substantially flat or low-sloped roofs or surfaces10. PV system 20 may comprise PV modules 30 and various connecting andsupporting equipment as will be described in more detail below. PVmodules will be referred to generically in the present disclosure as PVmodules 30 and more specifically as PV modules 30 a, 30 b, 30 c, 30 dwhen discussing PV modules 30 in relation to each other, such as adiscussion relating to the relative position of PV modules 30 in a PVsystem 20. Some embodiments may further comprise wind deflecting and/orballasting equipment as will also be described below. Some embodimentsdescribed in the instant disclosure may also be disclosed, described andshown in U.S. Provisional Patent Applications: 61/656,240 entitled:“Rail Mounted PV Apparatus, Method and System”, filed Jun. 6, 2012;61/698,292 entitled “Module Attachment System and Module SupportSystem”, filed Sep. 7, 2012; and 61/736,544 entitled “AncillaryApparatus, System and Method for Photovoltaic Modules”, filed Aug. 7,2012; each of which is incorporated by reference herein in its entirety.Throughout this document, like numbers will reference like parts,features, items or structures, even if they may be combined with or partof one or more different embodiment(s).

FIG. 1 shows a perspective view of an embodiment of a flat or low-slopedsupport structure, such as a roof or surface, the ground, a space,water, or land vehicle, or any structure or terrain with relatively mildslopes and/or contours, such as roof 10, with a system of components formounting a PV array on top of roof 10, such as PV system 20. An x, y, zcoordinate system as shown shall be referenced in this disclosure torefer to example directions and locations within PV system 20, thoughone skilled in the art will recognize that the axis or direction of anobject within system 20 may change while still being within the spiritand scope of the instant disclosure.

FIG. 2 shows a close-up view of the perspective view of FIG. 1, focusedroughly on the middle area of PV system 20. PV system 20 may comprise asupport structure, pan, corner support, or device for supporting some ofthe sides, edges, or corners of PV modules 30 a, 30 b, 30 c, 30 d, suchas support 40. Though other purposes and objects will be disclosedherein, supports 40 may be placed on roof 10 for at least one purposebeing the linking and supporting of PV modules 30 at a predeterminedangle (around or about the x-axis) and preventing, limiting orinhibiting PV modules 30 from being moved, shifted or blown off roof 10by the wind, seismic forces, or other similar exerted forces. Theinstant disclosure shows PV modules 30 being held by supports 40 at atilt angle of approximately 5 degrees around the x-axis, however otherangles, such as between 2-10, 5-15, 10-25 or 20-40 degrees areexplicitly contemplated and hereby disclosed. In some embodimentssupports 40 may also establish an electrical ground bond betweenadjacent PV modules 30, hold or retain wind deflectors 70, hold orretain ballast blocks or ballast trays 80 (FIG. 1), and/or providemeans, apparatus, systems or structures for managing, mounting,positioning, and/or connecting wires, conduit, wiring equipment, otherancillary equipment, and the like.

With additional reference to FIGS. 9-11, and as will be described inmore detail below, support 40 is shown comprising an upper pedestal orsupport portion, such as upper pedestal 41, for supporting an edge orcorner of PV module 30 a, 30 b, 30 c, 30 d that may typically, thoughnot necessarily, reside at a higher location along the z-axis thananother lower edge or corner; and a lower pedestal or support portion,such as lower pedestal 44, for supporting an edge or corner of PV module30 a, 30 b, 30 c, 30 d that may typically, though not necessarily,reside at a lower location along the z-axis than another higher edge orcorner. As shown in FIG. 2, upper pedestals 41 support upper edges 31 a,31 b, 31 c, 31 d of PV modules 30 a, 30 b, 30 c, 30 d, respectively, andlower pedestals 44 (not all visible in this view) support lower edges 32a, 32 b, 32 c, 32 d of PV modules 30 a, 30 b, 30 c, 30 d, respectively.As shown, supports 40 may support PV module 30 along edges near thecorners, though in other embodiments supports 40 may support edges notnear, or even far from, the corners. In still other embodiments supports40 may support the side edges 33 a, 33 b, 33 c, 33 d.

Support 40 may further comprise various other features such as upperpositioning tabs 42 and lower positioning tabs 45, for aiding in thepositioning of PV module 30, such as when it is being placed ontosupport 40; openings 43 for receiving lever clips 60 (see below);deflector tabs 46, 54, for holding a portion of a wind deflector 70 (seefurther description below); holes 47 for receiving wire ties or thelike; wire cutouts 48, for receiving wires or wire management devices,such as wire clips, bushings, connectors, restraints, etc. or the like;drop-in positioning tabs 49 for guiding modules 30 from a verticalposition down into the final mounted position as shown; slip sheet slots57 for retaining an edge of a slip sheet; and ballast pan tabs 53 and 51(not shown). Supports 40 may be placed directly on roof 10 as shown.High-side horizontal flange 50 and low-side horizontal flange 52 mayprovide surfaces approximately parallel with roof 10 for easy placementthereon. A surface area of flanges 50 and 52 may be large enough tosufficiently distribute a load of system 20 over roof 10. In someembodiments the surface area of flanges 50 and 52 may be lower thanshown here and in others it may be higher, depending on the amount ofpoint load distribution that may be required. In other embodimentssupports 40 comprise rubber pads and/or slip sheets underneath flanges50 and 52, for example, to prevent damage to a surface of roof 10.

Support 40 may be manufactured by cutting and/or stamping sheet metal,molding plastic, casting metal, or via other suitable manufacturingmethods. As shown in FIG. 9, support 40 may comprise a profile that isapproximately N-shaped or generally an upside-down U-shape with an uppervertical portion 55 and a lower vertical portion 56 that cant slightlyinward, thereby enabling supports 40 to be easily stackable forshipping. Other embodiments that contemplate other profiles forsupports, such as U-shaped, H-shaped, etc. and the like, are still inthe spirit and scope of the present disclosure and are explicitlycontemplated and disclosed herein, so long as such supports providepedestals for PV modules 30 and can connect PV modules 30 to supports,such as via lever clips 60, as will be discussed below.

FIG. 3 shows a perspective view of a bracket, spring clip, “dream clip”,“C-Lock”, lock, spring arm device, spring bracket, pivot-lock clip,lever clamp, or lever clip, such as lever clip 60, which is similar toother clips and clamps disclosed and shown in U.S. Provisional PatentApplications: 61/656,240 entitled “Rail Mounted PV Apparatus, Method andSystem” filed Jun. 6, 2012; 61/698,292 entitled “Module AttachmentSystem and Module Support System” filed Sep. 7, 2012; and 61/737,066entitled “Connecting Components for Photovoltaic Arrays” filed Dec. 13,2012; each of which is incorporated by reference herein in its entirety.Lever clip 60 may comprise a head 65, a lever or spring arm 66, and acatch or tab 67. Head 65 may comprise a slot, channel, opening, or notch68 bounded by an upper bump, tab, shelf, protrusion, flange, maleportion, or upper lip 64 and a lower bump, tab, shelf, protrusion,flange, male portion, or lower lip 61. Lip 64 may comprise an edge 63and lip 61 may comprise an edge 62 as will be discussed below.

FIGS. 4-6 show perspective views and FIG. 7 shows an end view (lookingstraight at the side of PV module 30 a) of a lever clip 60 beingutilized to connect PV module 30 a to support 40. Connection of modules30 to other locations on upper and lower pedestals 41 and 44 is similarexcept for the location of components relative to each other. Lever clip60 may be installed and/or operate as follows. First, lever clip 60 maybe oriented approximately as shown in FIG. 4 and FIG. 7 as position P1,then lever clip 60 may be moved toward PV module 30 a approximately inthe direction of the arrow in FIG. 4, inserting a portion of upper lip64 into groove 35 in frame 34 of PV module 30 a while lower lip 61 ispositioned underneath upper pedestal 41, as by inserting partiallythrough opening 43. The distance A (see FIGS. 3 and 7) is shown as theminimum distance between edges 62 and 63 and effectively defines theheight of notch 68. Distance A may be greater than distance B as shownin FIG. 7, which is the distance from the opening of groove 35 to thebottom of upper pedestal 41, such that notch 68 may fit around bothlower lip 36 of frame 34 and the full thickness of upper pedestal 41.

Once lever clip 60 is located in position P1, lever clip 60 may berotated in the direction of the arrow in FIG. 5, referred to herein asthe engaging direction (and generally clockwise around the y-axis inthis example), until edges 62 and 63 make contact with frame 34 and theunderside of upper pedestal 41, respectively, effectively positioninglever clip 60 in position P2. In position P2 edges 62 and 63 are justmaking contact. Installation continues with additional pressure beingapplied by the installer in the engaging direction, as shown by thearrow at P2 in FIG. 7. Since edges 62 and 63 are now engaging with frame34 and upper pedestal 41, the additional pressure may begin bending ofspring arm 66 as rotation continues; edges 62 and 63 may also cut intoframe 34 and pedestal 41 due to sharp edges, thereby creating a solidelectrical ground bond connection between frame 34 and support 40 and/orenabling clip 60 to resist lateral sliding relative to frame 34.

Once tab 67 is low enough, it may be pushed or otherwise encouraged inthe direction towards frame 34 until tab 67 is located at leastpartially inside groove 35 or at least partially under frame 34, thenlever clip 60 may be released. The action of releasing lever clip 60 mayresult in spring arm 66 exerting a spring force in a disengagingdirection, which is approximately opposite the engaging direction, oropposite arrows R1 in FIG. 7 (counterclockwise as shown, thoughoppositely shaped parts in other embodiments, see below, may work thesame except the rotational directions may be reversed). The release oflever clip 60 may now result in tab 67 moving upward slightly until itcatches inside groove 35, reaching a stable position, position P3 asshown in FIG. 6 and FIG. 7.

Lever clip 60 provides a novel mechanism for connecting PV modules tosupport structures. The basic theory of operation is better understoodby further reviewing FIG. 7. With lever clip 60 fully installed inposition P3, downward forces on PV module 30 a may be primarily resistedby upper pedestal 41 of support 40. Upward forces, such as wind uplift,may result in a force F1 being applied to edge 63 in the direction shownin FIG. 7. Since a principal portion resisting uplift force may be edge62, edge 62 under such load may effectively act as a pivot point andthus the disengaging direction of lever clip 60 may effectively be acounterclockwise rotation about edge 62. However, it may be relativelyeasy for lever clip 60 to resist movement in the disengaging directionsince (a) only a small component of force F1 is in the rotationaldisengaging direction since angle T is relatively small and thus theeffective moment arm C for force F1 acting about pivot 62 is relativelysmall, (b) spring arm 66 acts as a lever to resist rotation in thedisengaging direction with a substantial mechanical advantage, which maybe calculated as distance D minus distance C, then divided by distanceC, and (c) rotation in the disengaging direction, since the angle T isrelatively small, may require module 30 a to move laterally, yet module30 a, as shown, may also be held by at least 3 other lever clips 60, andsuch clips 60 may not all face the same direction (or operate in thesame rotational direction, see below), thereby further reducing the loadrequired to resist rotation in the disengaging direction. The lateralstability of a system of clips 60 may result, for example, from someclips 60 having a disengaging direction of clockwise and others having adisengaging direction of counterclockwise. Thus, lateral movements of PVmodule 30 a in both the positive and negative directions along thex-axis may result in some clips 60 opposing that movement since suchmovement may tend to further engage such clips 60.

Different embodiments contemplate different values for the angle T, withtypical values being in the range of 5 to 40 degrees; other typicalvalues may include 1-44, 5-15, 15-20, and 30-45 degrees. The mechanicaladvantage for spring arm 66 may be calculated as the ratio of thedistance D divided by the distance C as shown in FIG. 7. Withcontemplated typical lengths for spring arm 66 of 3-10 inches andlengths for the distance C in the range of 0.1 to 0.5 inches, typicalmechanical advantage ratios may be in the range of 6:1 up to 100:1.Other lengths and ratios are also explicitly contemplated.

In addition to providing substantial means, apparatus, systems orstructures for resisting rotation in the disengaging direction that maybe caused by force F1, and therefore maintaining a relatively secureconnection between PV module 30 a and support 40, including under anuplift load, lever clip 60 may provide other advantages as well. Forexample, since tab 67 on spring arm 66 may not be presented with largeloads during an uplift condition, as discussed above, spring arm 66 maycomprise a relatively low spring rate that enables easy bending ofspring arm 66 when moving from position P2 to position P3, thus makingit relatively easy to install lever clip 60 in the field. This may be incontrast to prior art systems where springs may be used in a manner thatforces the spring to resist loads directly, thereby requiring either astiff spring that is harder to install or a weaker spring that providespoor performance under load. When in position 3, spring arm 66 may alsoplace a significant pre-load on the connection joint between PV module30 a and support 40. This pre-load may be effectively amplified by themechanical advantage discussed above and may prevent movement within ajoint as long as F1 is lower than a relatively high value. Thus, inpractice the pre-load that spring arm 66 applies to a connection jointbetween PV module 30 a and support 40 may substantially stabilize theconnection and reduce wear over time due to cyclic loading (where suchcyclic loads act on the joint with less force than the effectivepre-load on the joint).

Lever clip 60 is shown in FIGS. 1-11 as requiring a generally clockwiserotation to connect PV modules 30 to supports 40. In other embodimentssimilar to PV system 20 lever clip 60 is partially or completelyreplaced by a lever clip that is the same as lever clip 60 except thatit is a mirror image and thus operates in the opposite direction(counterclockwise to engage instead of clockwise).

A typical installation sequence for the core components of PV system 20(supports 40, PV modules 30, and lever clips 60) may proceed as follows.First, supports 40 may be placed onto roof 10 in the approximatelocations shown in FIG. 1. Next PV modules are placed onto top ofsupports 40 in the positions shown. While there are numerous ways toplace modules 30 into supports 40, in one embodiment, supports 40 maycomprise upper and lower positioning tabs 42 and 45 to provide a hardstop that a module 30 may be slid up against to determine the correctposition for the mating parts relative to each other. PV modules 30 maybe installed by placing module 30 essentially vertically onto the slopejust above drop-in positioning tabs 49. Gravity may then assist asmodule 30 slides down slope and contacts tabs 49. Modules 30 may now berotated from an essentially vertical position down into a final mountedposition as shown. Once each module has been properly located on top ofthe 4 supports 40 that support it, then lever clips 60 may be installedaccording to the method described above. Each module 30 may be held byfour lever clips 60, in one embodiment as shown, with one lever clips 60near each corner. Lever clips 60 are shown installed at least partly inthe upper pedestals 41 in FIG. 9, but not installed in the lowerpedestals 44 so that module 30 a can be shown abutting positioning tab45 (see FIG. 13 for an example of how lever clip 60 may connect a module30 to lower pedestal 44).

The instant disclosure illustrates optional accessories such as winddeflectors 70 and ballast pans 80 (as will be discussed in more detailbelow) as well as other auxiliary or ancillary devices (some of whichare disclosed or described herein, or in the documents incorporated byreference herein) which may be combined or attached to PV modules ormounting systems and apparatus. Such accessories are not necessarilyrequired, but in some cases there may be benefits to including suchdevices. For example, wind uplift forces on PV system 20 may be reducedin certain cases if wind deflectors 70 are included on some or all PVmodules 30. In other cases the provision of ballast pans 80 may enablethe addition of ballast blocks 81 to PV system 20, which may reduce,minimize or eliminate the need for penetrating roof 10 with screws tosecure PV system 20 to roof 10. While the embodiments shown in FIGS.1-11 shows optional wind deflector 70 and ballast pan 80, otherembodiments may include structures or systems essentially identical tothe embodiments in FIGS. 1-11 except that they do not include winddeflector 70 or ballast pan 80. Further embodiments are essentiallyidentical to the embodiment in FIGS. 1-11 except they do not includewind deflector 70 yet they may include ballast pan 80. Other embodimentsare essentially identical to the embodiments in FIGS. 1-11 except theydo not include ballast pan 80 yet they do include wind deflector 70.

FIGS. 8-11 provide more details regarding wind deflector 70 and ballastpan 80. FIG. 8 shows a close-up view of the perspective view in FIG. 1that focuses on optional wind deflector 70 located behind module 30 a.FIG. 9 shows a side view of PV system 20 and FIG. 10 shows a close-up ofregion A in FIG. 9.

It is hereby contemplated and disclosed that wind deflector 70 may bemade, produced or constructed out of relatively thin sheet or castmetal, plastic, ceramic, composite, or the like. Wind deflector 70 maycomprise two flaps 71L, 71R located at opposite ends of deflector 70 forthe purpose of inserting behind deflector tabs 46, such as in order tohold deflector 70 in place. Deflector 70 may also comprise a lower edgeor flap 73 for inserting behind deflector tabs 54, such as in order tofurther retain deflector 70. Flap 73 may be bent at a slightlyoutward-facing angle relative to lower vertical portion 77 so thatinsertion of flap 73 behind flaps 54 then rotating upward to insertflaps 71L, 71R behind deflector tabs 46 results in partial bending offlap 73 and a pre-loaded tight fit behind tab 54. It is noteworthy inthis embodiment that flap 73 is located essentially fully behind tab 54as shown in FIG. 8 and at 72 in FIG. 10, but since tabs 54 are short,flap 73 is only deformed right at tab 54 and thus appears in FIG. 10 tothe right of tab 54 since that is where it exists in the region behindtab 54.

A typical installation sequence for wind deflector 70 may proceed asfollows. First, the core components of PV system 20 (supports 40, PVmodules 30, and lever clips 60) may be installed on roof 10, aspreviously described or in another manner. Next deflector 70 may bepositioned close to its final position as shown in FIG. 8, exceptrotated away from module 30 a slightly such that flap 73 is slightlyhigher than tabs 54 and approximately parallel with upper verticalportion 55. Deflector 70 is inserted behind tabs 54, then pushed all theway down, then rotated back toward module 30 a until such flaps 71L and71R are past tabs 46. Deflector 70 may now be rotated back away frommodule 30 a slightly as flaps 71L and 71R are tucked behind tabs 46.

Wind deflector 70 may further comprise pre-stressed conduit knockouts 78for connecting to conduit fittings and perforated portions 79, and maybe used for bending down even with flaps 71L, 71R at the end of a rowwhen it is desired to slide support 40 fully up under PV module 30.

Prior art wind deflectors typically comprise a wind deflector for thepurposes of (a) preventing air from impinging on the under-side of a PVmodule and producing lift, and (b) reducing drag when wind strikes thedeflector straight-on (from the rear or high side) which might cause aPV array to slide along a roof. Thus, wind deflectors in such systemstypically block the high side to prevent wind from striking the backsideof the PV module and angle the deflector to reduce drag; therefore suchprior deflectors may have only attempted to serve their purpose when thewind is directed toward the high side of the module. Some prior systemshave attempted to reduce lift by also including vent holes intended toensure equal pressure on the topside and underside of the PV module.However, such attempts have not taught vent locations that connectspecific lower pressure regions on the topside of a PV module with theunderside of the PV module.

Referring more specifically to FIGS. 10-11, wind deflector may comprisea special shape optimized to reduce uplift forces on PV modules 30 dueto wind. Wind deflector 70 may comprise a lower vertical portion 77, anoutward angled portion 76 that allows deflector 70 to go all the way upnear a top surface of PV module 30, and an upper vertical portion 74that ends in a small top flange 75 that may angle back over toward PVmodule 30 a, for example to enhance air flow characteristics. Uppervertical portion 74 is positioned, for example to leave a gap 99 betweenwind deflector 70 and PV module 30 a.

At the wind speeds encountered by a PV array, the fluid (air) may beviewed as essentially incompressible. Therefore, Bernoulli's Principlemay apply: an increase in the speed of the fluid may be accompanied by adecrease in pressure. PV module 30 and deflector 70 effectively reducethe cross section of the air stream (when the air stream is flowing asshown in FIG. 11). In order to maintain the same flow rate with thisreduced cross section, the velocity of the air stream increases. Andthis velocity reaches a maximum near apex 98 where module 30 anddeflector 70 meet. Deflector 70 creates a gap 99 between deflector 70and module 30, located at apex 98 where the fluid velocity is high andthe pressure is low, thereby connecting the underside of PV modules 30with the low pressure zone at apex 98. This arrangement may draw air outof gap 99 as indicated by the upward arrow at apex 98 and may furtherresult in lower pressure on the underside of PV modules 30 and areduction in total lift. Similar effects may also result when the winddirection is other than shown.

FIGS. 1 and 9-11 show a weight or ballast holding, supporting orcarrying device, such as ballast pan 80 and one or more heavy object(s),block(s), stone(s), sand, or highly dense material(s), such as ballastblock 81. As shown in FIG. 9, ballast pan 80 may link high-sidehorizontal flange 50 with a corresponding low-side horizontal flange 52on a next row of supports 40. Ballast pan 80 may be approximately thesame width as or slightly less than the width of support 40 as shown inFIG. 1 and may comprise substantially vertical walls 82. Walls 82 may beof sufficient rigidity along the z-axis to prevent ballast pan 80 fromsagging under the weight of blocks 81 and thereby maintaining a gap 83between roof 10 and ballast pan 80. Gap 83 may reduce costs of aphotovoltaic array mounting apparatus or system, since protectivematerial such as a slip sheet may not be required between ballast pan 80and roof 10. Ballast pan 80 may be sized to carry anywhere from 1 to 5ballast blocks 81 (or more), thereby enabling the easy addition ofweight as needed to resist uplift forces.

FIG. 12 shows a perspective view of an embodiment of a PV system 1220,similar to that shown in FIGS. 1-11, except wind deflector 70 isreplaced by wind deflector 1270. Wind deflector 1270 is similar todeflector 70 except that perforated portions 79 are not present andflaps 71L, 71R have been replaced with flaps 1271L, 1271R, which aresimilar but longer. Lone flaps 1271L, 1271R allow for sliding-in ofsupports 40 at the end of a row without having to bend perforatedportions 79 as described above. For example, support 40 at the end ofthe row on the high side of PV module 30 a is shown in a position thatis essentially fully underneath PV module 30 a and covering most of flap1271L; whereas support 40 between PV modules 30 a and 30 b is roughlycentered between the two PV modules and thus a substantial portion offlap 1271L is showing/exposed (to the right of support 40 in FIG. 12).

FIG. 13 shows a perspective view of an embodiment of a support 1340supporting PV module 30. Support 1340 may be similar to support 40except that support 1340 may further comprise a ballast support deviceor ballast tray 1395 located substantially beneath support 1340. Ballasttray 1395 may comprise one or more ballast blocks 1381, a channel 1397and a lip 1396. Support 1340 may comprise high-side horizontal flange1350 and low-side horizontal flange 1352, which may be similar toflanges 50 and 52 except optimized for connection to ballast tray 1395.Ballast tray 1395 may be connected to support 1340 prior to installationof PV module 30, as by laying tray 1395 on roof 10, lifting support 1340up, angling support 1340 slightly downward on the high side, insertingflange 1350 into channel 1397, and then pushing down on a low side tosnap flange 1352 behind lip 1396.

FIGS. 14-15 show an embodiment of a positive attachment device for useas a replacement for wind deflector 70 and/or ballast pan 80 or as acomplement to wind deflector 70 and/or ballast pan 80 in the embodimentsshown in FIGS. 1-11. It is known in the art to utilize a positiveattachment mechanism, such as a screw, to connect a PV system to a roofor other structure. However, the instant disclosure shows a novel means,apparatus, systems or structures for providing positive attachments byutilizing a variably positionable bracket that connects directly to alow-side and/or a high-side of PV module frames.

FIG. 14 shows a perspective view of a PV system 1420 comprising PVmodules 30, supports 40 (not shown), and a positive attachment device orvariably positionable bracket, such as bracket 1400. FIG. 15 shows aside view of PV system 1420. In this example, bracket 1400 effectivelyreplaces a support 40 from the end of a row of PV modules 30. One ofskill in the art will recognize that brackets 1400 may also be placed inother locations within a row of PV modules 30, in many places betweensupports 40. In some embodiments where seismic loads are significant,brackets 1400 may be distributed throughout PV system 1420, for exampleto resist lateral seismic loads. In other embodiments bracket 1400completely replace some or all supports 40.

Bracket 1400 may comprise a generally U-shaped profile having a base1403, a high-side vertical portion 1401, and a low-side vertical portion1402. Other embodiments provide other shapes that still achieve the samebasic functionality as described above and/or below. Vertical portions1401 and 1402 may be connected to PV modules 30 via fastener 1409. Inthe instant disclosure fastener 1409 may be a quarter-turn device thatmay lock into groove 35 in frame 34 to secure bracket 1400 to both PVmodules 30 c and 30 a. Fastener 1409 may connect substantially anywherealong a length of frame 34, thereby allowing bracket 34 to be variablypositioned in order to align bracket 1400 with a structural memberand/or optimally position bracket 1400 with respect to resisting loadspresented to PV modules 30. Bracket 1400 may further comprise a block1404 a base plate 1406 and a flashing or roofing material 1407. Base1403 may comprise holes or slots to accommodate a fastener 1405 forconnecting bracket to a block 1404 and base plate may comprise one ormore fasteners 1408 for connecting to a structure, such as a sheathing,a purlin, a girder, a beam, a rafter, or the like, below.

FIGS. 16-17 show an embodiment of a positive attachment device orbracket 1600 that achieves similar functionality to bracket 1400, exceptbracket 1600 may be located beneath PV modules 30 instead of between PVmodules 30, and bracket 1600 may be variably positioned along both the xand y axes.

FIG. 16 shows a perspective view of a PV system 1620 that is similar toPV system 1420 except that bracket 1400 is replaced by bracket 1600.FIG. 16 also includes PV modules 1630 which are essentially the same asPV modules 30 except that the PV laminate has been removed from the viewfor clarity and so that bracket 1600 below may be revealed. In an actualinstallation, PV modules 1630 may be replaced by PV modules 30. FIG. 16also shows roof 1610 as only comprising rafters 1615 (no sheathing isshown). Other embodiments comprise roofs with other typical roofstructures. FIG. 17 shows a side view of PV system 1620.

Bracket 1600 may comprise a long member 1603 spanning most of the widthof PV module 1630 and comprising slots or holes for receiving fastener1605 which may connect long member 1603 to block 1604. Bracket 1600 mayfurther comprise upper flat portion 1601 and lower flat portion 1602that run approximately in the plane (or an essentially parallel plane)of PV module 1630, are located essentially directly beneath PV moduleframe 1634, and may be connected to frame 1634, as via lever clips 60.Bracket 1600 may further comprise a base plate 1606 (FIG. 16) and aflashing or roofing material 1607 (FIG. 16). Base plate 1606 maycomprise one or more fasteners 1608, as for connecting to rafter 1615.Bracket 1600 may be variably positioned along the x-axis by connectingsubstantially anywhere along a length of frame 1604 via lever clips 60.Block 1604 may be variably positioned along the y-axis by connectingfastener 1605 through different holes or slots in member 1603. Thus,bracket 1600 has the ability to vary the connection point for fastener1608 along one or both the x and y axes, enhancing the flexibility forwhere bracket 1600 connects to rafters 1615.

FIGS. 18-23 show an embodiment of a PV system 1820 comprising PV moduleswith no groove on the outside surface, such as PV modules 1830 a, 1830b, 1830 c, 1830 d. FIG. 18 shows a perspective view of PV system 1820,FIG. 22 shows a side view of PV system 1820, and FIG. 23 shows aclose-up of the portion of FIG. 22 inside the circle A. PV system 1820comprises many of the same elements as PV system 20, including but notlimited to, supports 40, wind deflectors 70, and ballast pans 80. Asnoted above, lever clips may come in mirror image variants that reversethe direction of rotation of the clip during installation. PV system1820 provides an example of how pairs of such lever clips may worktogether in a system. PV system 1820 may comprise acounterclockwise-rotating lever clip, such as lever clip 1860 a, and aclockwise-rotating lever clip, such as lever clip 1860 b. Lever clip1860 b may work in a very similar manner to lever clip 60 except that:(a) notch 68 is replaced by notch 1868 which is wider and thus capableof going around an entire PV module frame 1834 and upper pedestal 41,(b) spring arm 1866 may be stiffer than spring arm 66 and bends verylittle when rotated into a final position, and (c) tab 1867, whichreplaces tab 67, may be optimized to catch underneath frame 1834 insteadof inside a groove 35 of frame 34.

FIGS. 19-21 show perspective views of an exemplar installation sequencefor lever clip 1860 a. In FIG. 19 lever clip 1860 a is shown completelyunattached and ready to be installed. Note head 1865, which is similarto head 65, comprises upper lip 1864 and lower lip 1861 which functionessentially the same as upper and lower lips 64 and 61 respectivelyexcept that the direction of rotation is reversed so edges 1862 (notviewable here) and 1863 are on the opposite sides from edges 62 and 63and, since spring arm 1866 is stiffer, edges 1862 and 1863 may cut intoframe 1834 deeper than edges 62 and 63 when being rotated into position.FIG. 20 shows lever clip 1860 a inserted and in position PP1, which iseffectively the same as position P1 except that a different lever clipis being installed. FIG. 21 shows lever clip 1860 a fully rotated andlocked in at position PP3, which is effectively the same as position P3except that a different lever clip is being installed. Note that stiffspring arm 1866 is essentially straight in position PP3 with most of thepre-load, as discussed above, being provided by the cutting in of edges1862 and 1863, and the inherent spring back force that frame 1834provides beneath edges 1862 and 1863. While the instant embodimentdemonstrates lever clips that are opposite with respect to the engagingdirection of rotation, one of skill in the art will also recognize thatother variants are also within the scope of the instant disclosure. Forexample, in other embodiments spring arm 1866 connects to the head oflever clip 1860 a at the bottom near lip 1861 instead of at the top nearlip 1864, thereby resulting in an installation action whereby theinstaller pulls upward and attaches tab 1867 on top of frame 34 insteadof underneath it.

FIGS. 24-29 show an embodiment of PV system 2420 which may be similar toPV system 20 except the locations and orientation of certain equipmentmay be different and lever clip 60 and support 40 may be slightlyaltered or modified. FIG. 24 shows a perspective view of a first PVmodule 30 b of PV system 2420 in the process of being installed and FIG.25 shows a perspective view with PV module 30 b installed and a secondPV module 30 a being installed. A portion of PV module 30 a is shownremoved in FIG. 25 to reveal components below.

PV system 2420 shows PV modules 30 tilted around the x-axis, as in PVsystem 20, except here PV modules 30 are tilted such that the short sideof each PV module 30 is the high side (thus modules are oriented in aportrait configuration instead of landscape with respect to the y-axis).One of skill in the art will recognize that both PV system 20 and PVsystem 2420 may be oriented in either landscape or portraitconfiguration (or other configuration, including combinations).

Support 2440 may be similar to support 40 except that it may besupporting PV modules 30 along their y-axis edges instead of along theirx-axis edges. Support 2440 may comprise a body portion 2455 extendingalong and substantially beneath adjacent edges of PV modules 30 a and 30b. Body portion 2455 may comprise an upper pedestal with a platformangled around the x-axis, such as upper pedestal 2441, and a lowerpedestal with a platform at approximately the same angle and inapproximately the same plane as upper pedestal 2441, such as lowerpedestal 2444. PV modules 30 may be placed onto and supported by upperand lower pedestals 2441 and 2444.

PV system 2420 may further comprise lever clips similar to lever clips60 but adapted to work with supports 2440. FIG. 26 shows a perspectiveview of a bracket, spring clip, “dream clip”, “T-Lock”, “J-Lock”, lock,spring arm device, spring bracket, pivot-lock clip, lever clamp, orlever clip, such as lever clip 2460. Lever clip 2460 may be similar tolever clip 60 except lip 64 may be replaced by lips 2464 a and 2464 b sothat two PV modules 30 may be connected simultaneously and lip 61 may bereplaced by lip 2461 so that an orthogonally located support portion(instead of one that is parallel to an edge of PV module 30) may beconnected to PV module 30. Lips 2464 a and 2464 b may comprisecorresponding edges 2463 a and 2463 b that serve a similar function toedge 63 when clip 2460 is installed. Lip 2461 may comprise an edge, suchas edge 2462, that performs a similar function as edge 62, except thatedge 2462 may press against an underside of a support that is crossingmodule 30 edge orthogonally, such as upper pedestal 2441 or lowerpedestal 2444.

FIG. 27 shows a front view close-up showing the area between PV modules30 a, 30 b as shown in FIG. 25. FIG. 28 shows a perspective view frombeneath PV system 2420 in the area near support 2440.

PV system 2420 may be installed as follows, in a step-by-step-basedprocess similar to those described above. Supports 2440 may be placedonto a surface, such as roof 10. PV module 30 b may be placed onto twosupports 2440 as shown in FIG. 24 (second support not visible here, butit is located beneath the edge opposite of the edge being supported bythe viewable support 2440). Lever clips 2460 connecting PV module 30 bto support 2440 (the one not viewable) may be fully installed since thismay end up as, or become, the end-module on a row of PV modules 30.Next, another support 2440 is placed approximately one-module's widthover from module 30 b, and then module 30 a is placed thereon as shownin FIG. 25. With both modules 30 a, 30 b in place, lever clips 2460located in the space between PV modules 30 a, 30 b may be rotated intoposition 3 (see above), thereby connecting PV modules 30 a and 30 b tosupport 2440. FIGS. 27 and 28 provide additional views of a gap betweenPV modules 30 a, 30 b with lever clips 2460 connecting PV modules 30 a,30 b to upper and lower pedestals 2441 and 2444, respectively.

In an embodiment similar to PV system 2420, lever clip 2460 is replacedby lever clip 2960 as shown in the perspective view of FIG. 29. Leverclip 2960 is similar to lever clip 2460 except that lip 2464 b has beenremoved, thereby removing the ability for this embodiment of a leverclip to simultaneously connect two PV modules to a support. Thisdifference may have advantages in some situations. For example, wheninstalling lever clips 2960 according to the installation proceduredescribed above for PV system 2420 (except substituting lever clips 2960for lever clips 2460), an installer may fully secure supports 2440 toeach module 30 independently, thereby preventing the need for aligningPV modules 30 a, 30 b prior to installing lever clip 2960. Lever clips2960 may be installed on opposite sides of upper and lower pedestals2441 and 2444 and in opposite directions, which may result in betterperformance under certain shear loads.

FIGS. 30-32 show an embodiment of a PV system 3020 that is similar incertain respects to PV system 20 and PV system 2420. For example, PVsystem 3020 may comprise supports along both x-axis PV module 30 edgesand y-axis PV module 30 edges (instead of one or the other).

FIG. 30 shows a perspective view of a first PV module 30 b of PV system3020 in the process of being installed and FIG. 32 shows a perspectiveview with PV module 30 b of PV system 3020 already installed and asecond PV module 30 a of PV system 3020 being installed. A portion of PVmodule 30 a is shown removed in FIG. 32 to reveal components below. FIG.31 shows a perspective view of a close-up of a corner of PV module 30 bfrom FIG. 30 (corner comprising a support as discussed below).

PV system 3020 shows PV modules 30 tilted around the x-axis, as in PVsystem 2420. Support 3040 may be similar to support 2440 except that itmay be shorter and only intended to support PV module 30 in one locationinstead of two as with support 2440. For example, as shown in FIG. 32,supports 3040 may primarily provide support to the upper portions of PVmodules 30 a, 30 b, whereas a second support, shown as support 3140, mayprovide support for lower portions of PV modules 30 a, 30 b. Support3040 may comprise an upper pedestal with a platform angled around thex-axis, such as upper pedestal 3041, which may be adapted to connect toPV modules 30 via a lever clip, such as lever clip 2960, and may besimilar in terms of functionality to upper pedestal 2441.

PV system 3020 may further comprise a lower support for supporting oneor two PV modules along a lower edge, such as support 3140. As shown inFIG. 31, support 3140 may comprise two lower pedestals, such as lowerpedestals 3144 a and 3144 b, each for supporting a lower edge of a PVmodule 30 and each in approximately the same plane as upper pedestals3041 when PV system 3020 is installed on a relatively flat surface.Upper pedestals 3041 and lower pedestals 3144 a, 3144 b may connect toPV modules 30 via lever clips 2960 as described above. Support 3140 mayfurther comprise a substantially vertical portion 3142 and a flange3159, which may be used, for example, to provide additional resistanceto uplift loads. Flange 3159 may be inserted inside groove 35 or aboveframe 34 so long as it provides a positive stop to resist upwardmovement of PV module 30.

PV system 3020 may be installed as follows. Supports 3040 and 3140 maybe placed onto a surface, such as roof 10. PV module 30 b may be placedonto two supports 3040 as shown in FIG. 30 (second support not visiblehere, but it is beneath the edge opposite of the edge being supported bythe viewable support 3040) and one support 3140. Both lever clips 2960connecting PV module 30 b to supports 3040 (one visible and one notvisible here) and lever clip 2960 connecting PV module 30 b to support3140 may be fully installed as shown in FIG. 31. Next, another support3040 and another support 3140 are placed approximately one-module'swidth over from module 30 b, and then module 30 a is placed thereon asshown in FIG. 32; the second support 3140 is not shown here as it maynot be required at the end of a row. In other embodiments a support 3140is used at the end of a row and it is slid inward from the positionshown in FIG. 30 such that it does not protrude from the end of the row.The installation as shown in FIG. 32 is completed by connecting PVmodule 30 a to supports 3040 and 3140 (if utilized at the end of therow) with lever clips 2960.

FIGS. 33-35 show an embodiment of a PV system that is similar to PVsystem 3020 except that supports 3040 and 3140 are replaced by a support3340 that combines the functionality of supports 3040 and 3140 into onepart and links them by a bar 3365 that may provide a structuralconnection between rows. FIG. 33 shows a perspective view of PV system3320 and FIGS. 34 and 35 show close-up details of circles A and B inFIG. 33. Lever clips 2960 or 2460 may be used to connect PV modules 30to support 3340, though support 3340 is shown without lever clipsinstalled. Support 3140 may be used at the end of a column as shown inFIG. 33. In other embodiments support 3340 may be used throughout.

FIGS. 36-37 show an embodiment of a PV system 3620 that is similar to PVsystem 20 except that supports 40 and lever clips 60 are replaced byrear supports 3640 and front supports 3740. Rear and front supports 3640and 3740 may be connected to frames 34 via fastener 3760 that may rotateand lock into groove 35.

FIGS. 38-39 show perspective views of an embodiment of a PV system 3820comprising a ballast pan, such as ballast pan 3880, which may be similarto ballast pan 80 except that it may principally extend in the spacebetween, in front of, or behind rows of PV modules 30 instead of, forexample, extending beneath PV modules 30. In some embodiments ballastpan 3880 may be used instead of or in addition to ballast pan 80. FIG.38 shows ballast pan 3880 installed in front of modules 30 c, 30 d(which are installed on supports 40 with lever clips 60 as describedabove in FIGS. 1-11). FIG. 38 shows ballast pan 3880 just afterinstallation and before installation of module 30 d.

Ballast pan 3880 may comprise walls 3882 for providing stiffness in thez-axis direction and flaps 3883, 3884. Ballast pan 3880 may be installedby sliding straight down and over support 40 into the position shown inFIG. 39. Flaps 3883 and 3884 may interfere with support 40 and thus bendoutward to provide a spring load or pre-load between ballast pan 3880and support 40. Ballast pan 3880 may further comprise cutouts 3885 thatleave places to step when an installer may be walking between rows of PVmodules 30 in PV system 3820. Ballast blocks 3881 may be placed on topof ballast pan 3880. Walls 3882 may be stiff enough to prevent ballastpan from sagging down and touching roof 10.

Some benefits of PV systems 20, 1220, 1420, 1620, 1820, 2420, 3020,3320, 3620, 3820 as shown herein may include:

Compatible with many types of roofs and structures;

Simple to install and low part count;

Easy to ship due to nesting of components such as supports;

Few or no tools required for installation since lever clips may berotated into position by hand;

Good performance in uplift even with hand-installable spring levers dueto innovative lever clip design;

Ground bonds created automatically during installation of equipment;

Low cost compared to prior art systems; and

Compatible with grooved PV modules as well as PV modules comprising asubstantially flat outward facing surface on the frame.

Other benefits and variations on the features, uses and structures ofthe various embodiments explicitly disclosed herein may occur to one ofskill on the art and are included in this instant disclosure.

Referring now to FIG. 1, a PV array is shown installed upon a flat andlevel or low-slope surface. A PV array such as PV array 20 may includePV modules 30A-30D, supports 40, ballast pans 80, and vertical walls 82.

Referring now to FIG. 2, an enlarged section of PV array 20 is shown. PVarray 20 may further include lever clips 60 and wind deflectors 70.Supports 40 may include an upper surface or pedestal 41, a lower surfaceor pedestal 44, tabs 42 and openings 43. Lever clips 60 may include anotch 68 and an arm 66. As shown in FIGS. 1 and 2, supports 40 may bearranged on a substantially level or low-slope surfaces such as roof 10in rows and columns. The distance between neighboring supports 40 in arow may be less than the length of the longest side of a PV module 30.The distance between neighboring supports 40 in a column may be lessthat the length of the shortest side of a PV module 30. PV modules 30may be placed on supports 40 such that each corner of the PV module 30rests on a support 40. The PV module 30 may abut one or more tabs 42,which may align the PV modules 30 on the supports 40 and reduce motionof the PV modules 30 with relation to the supports 40. Clips 60 mayengage the frame or a portion of the frame of a PV module 30 and anopening 43 of a support 40 to secure the PV module 30 to the support 40.Clip 60 may penetrate the frame of a PV module 30 and create anelectrical grounding bond between the PV module 30, clip 60, and support40.

Referring now to FIGS. 14 and 15, another embodiment of a PV array isshown installed upon a flat and level or low-slope surface. A PV arraysuch as PV array 1420 is similar to PV array 20 as shown and describedin FIG. 1 and others, and to other PV arrays. PV array 1420 may includea bracket such as bracket 1400. Bracket 1400 may connect to PV module30C and PV module 30A using fasteners 1409, and may further connect to asurface or substrate using a fastener 1405. The bracket 1400, installed,may reduce or eliminate movement or other disruption to the PV array1420 caused by wind or seismic activity.

FIGS. 40A to 40H are illustrations of an optional fastener 4101 that canbe substituted for lever clips 60 as previously described herein. FIGS.41A and 41B show the installation of fastener 4101 into the side grooveof a photovoltaic module. As will be explained, fasteners 4101 rotate tolock the photovoltaic modules 30 onto the supports 40.

Fastener 4101 comprises a hook portion 4102 and a coupling portion 4103.Hook portion 4102 comprises a hook 4104 and a body portion 4105 with acurved lower surface 4106 and an aperture 4107 passing therethrough.Coupling portion 4103 is received through aperture 4107 and comprises abody portion 4116, a lever 4115 with a catch or catches 4123A and 4123B.As will be shown, rotation of coupling portion 4103 with respect to hookportion 4102 causes catches 4123A and 4123B to rotate with respect tohook portion 4102.

Aperture 4107 may comprise a circular portion 4108 and one or morenon-circular portions 4109A and 4109B and one or more risers 4110A and4110B that create one or more recesses 4111A and 4111B. Coupling portion4103 may comprise: a lever 4115 with an inner portion 4112 and an outerportion 4113 that meet at an angle 4114; a large cylinder 4116; a smallcylinder 4117 with a lip 4118; a neck 4119 with one or more curvedsurfaces 4120A to 4120D and one or more flat surfaces 4121A to 4121Dthat create one or more ridges 4122A to 4122D; and one or more catches4123A and 4123B and a spacer 4124.

Hook 4104 may extend downwardly and backwardly from body portion 4105,as shown.

Coupling portion 4103 may be inserted into aperture 4107 of hook portion4102 by orienting lever 4115 such that it extends downward and catches4123A and 4123B such that they extend laterally from neck 4119 and alignwith non-circular portions 4109A and 4109B. The shape of aperture 4107may prevent coupling portion 4103 from being inserted into aperture 4107in any other orientation. Coupling portion 4103 may rotate once insertedinto aperture 4107 such that rotation may cause lip 4118 to move intorecesses 4111A and 4111B and overlap riser 4110A or 4110B, therebypreventing coupling 4103 from disengaging hook portion 4102. Lever 4115may extend outward from the rear-most portion of large cylinder 4116.Small cylinder 4117 may extend forward from the front-most portion oflarge cylinder 4116 and may be concentric with large cylinder 4116. Neck4119 comprising curved surfaces 4120A to 4120D and flat surfaces 4121Ato 4121D that extend from small cylinder 4117 and may be off center andnon-concentric with small cylinder 4117. Neck 4119 has a center axis A1passing therethrough and cylinder 4117 has a center axis A2 passingtherethrough. Catches 4123A and 4123B may extend outward from the frontmost end of neck 4119, or from elsewhere along neck 4119. Spacer 4124may extend forward from neck 4119. Catches 4123A and 4123B may beangled, rounded or a combination of angled and rounded.

FIG. 41A and FIG. 41B show how fastener 4101 is connected to the sidegroove in a frame of modules 30. Fastener 4201 is similar to fastener4101 as shown and described. Frame 4231 includes groove 4232 with upperlip 4233, lower lip 4234, upper channel 4235, and lower channel 4236.Prior to connecting to frame 4231, hook 4204 may be hooked into opening43 in support 40 (as was seen in FIGS. 2 and 4). Lever 4215 may then berotated upwardly, causing catches 4223A and 4223B to extendhorizontally, aligning with groove 4232. Coupling portion 4203 may thenbe inserted into groove 4232 such that neck 4219 is between upper lip4322 and lower lip 4234 and catches 4223A and 4223B align with upperchannel 4235 and lower channel 4236. Lever 4215 may then be rotatedclockwise, pressing catch 4223A into upper channel 4235 and catch 4223Binto lower channel 4236. This rotation may lift frame 4231 upward onemillimeter (or some other distance), because neck 4219 is not centeredwith any other rotating portions of coupling portion 4203. For example,as seen in FIG. 40H, coupling portion 4103 (with its associatedcylindrical portion 4117) will rotate about its center axis A2 therebylifting neck portion 4119 such that the central axis A1 of neck portion4119 will be positioned directly above axis A2 (as seen in thepositional orientation of FIG. 40G). This lift may create space betweenframe 4231 and support 40 to allow for thermal expansion. This rotationmay further secure frame 4231 to fastener 4201 and create preload byvirtue of the force used to rotate neck 4219 against upper lip 4233 andlower lip 4234, which may partially deform frame 4231. This rotation mayfurther create an electrical grounding between coupling portion 4203 andframe 4231 as the ridges of neck 4219 distort the inner surfaces of thegroove 4231, thus creating metal-to-metal contact between coupling 4203and frame 4231. Curved lower surface 4206 may then contact support 40and may pivot, swivel or rock laterally to allow for thermal expansion.Lever 4215 may prevent over rotation because it will contact anothersupport 40, thus preventing over-rotation.

While a number of exemplary aspects and embodiments have been discussedabove, those of skill in the art will recognize certain modifications,permutations, additions and sub-combinations thereof. It is thereforeintended that the following appended claims and claims hereafterintroduced be interpreted to include all such modifications,permutations, additions, and sub-combinations as are within their truespirit and scope.

What is claimed is:
 1. A fastener for securing a photovoltaic module toa support, comprising: (a) a hook portion comprising: (i) a body portionwith an aperture passing therethrough, and (ii) a hook extending fromthe body portion; and (b) a coupling portion received through theaperture in the body portion, the coupling portion comprising: (i) abody portion having a first part received within the aperture in thebody portion of the hook portion and a second part projecting out of theaperture in the body portion of the hook portion, wherein the first andsecond parts are not concentric; (ii) a lever on the body portion of thecoupling portion, the lever extending from the first part of the bodyportion of the coupling portion, and (iii) a pair of catches extendingradially outwardly from opposite sides of the second part of the bodyportion of the coupling portion, wherein rotation of the couplingportion with respect to the hook portion causes the pair of catches torotate with respect to the hook portion and causes the second part ofthe body portion of the coupling portion to move up or down.
 2. Thefastener of claim 1, wherein the aperture in the body portion of thehook portion has a riser running partially therearound.
 3. The fastenerof claim 1, wherein the hook extends from the hook portion body portionin an opposite direction from the pair of catches.
 4. The fastener ofclaim 1, wherein each of the pair of catches have angled or roundedsurfaces.
 5. The fastener of claim 1, wherein the catches aredimensioned to be received into a side groove in a photovoltaic moduleframe.